Two Side Cut Reseal With Pressure Sensitive Adhesive and the Method for Making Same

ABSTRACT

Two side cut reseal with pressure sensitive adhesive. A flexible package having a reseal integrated within the opposite layers of its film is constructed using existing vertical form fill and seal packaging machines. The invention involves a single sheet of flexible packaging film web having at least three layers. In a preferred embodiment, the reseal is comprised of two offsetting score lines on interior and exterior sides of the film and spaced apart by 0.5 to 1 inch. The scoring creates lines of weakness, which define an opening in the package. Upon opening, a pressure sensitive adhesive layer, which is pattern applied in between the offsetting score lines, is exposed from an interior side of the film. The adhesive releasably adheres the inner and outer layers of the film back together once separated by a consumer.

BACKGROUND OF THE INVENTION

1. Technical Field

The present invention relates to a flexible bag formed on a verticalform fill, and seal machine having a resealable opening near the top,and the method for making same. The invention allows for use of existingpackaging technology to produce a flexible package with adhesive capableof resealing an opening in the bag without disturbing food products at alow cost.

2. Description of Related Art

Snack foods and other items are often packaged in bags formed from thin,flexible packaging films. These thin films are formed primarily ofplastics, such as polypropylene and polyethylene, but can also containmetalized films, foil, paper, or oriented films. These packaging filmscan have numerous layers directed to achieving specific needs, but aregenerally formed at least in part by extrusion of a plastic layer,co-extrusion of multiple layers simultaneously, extrusion coating ofanother material (such as paper), and the lamination of two layerstogether via either extrusion lamination or adhesive lamination. Thepackaging film used in such process is typically a composite polymermaterial produced by a film converter.

A typical film 100 ideally suited for use on vertical form and fillmachines for the packaging of food products is seen in FIG. 1. The outerlayer 102 is typically an OPP layer, short for oriented polypropylene,while the inner layer 106 is usually a metalized OPP. The use of athermoplastic polymer such as OPP or Polyethylene terephthalate (PET)for the outer layer 102 and the inside layer 106 further makes itpossible to heat seal any surface of the film to any other surface informing either the transverse seals or back seal of a package.Sandwiched between the outer layers 102 and inner layer 106 is a middlelayer 104, which is typically either an adhesive or polyethylene. Theinner, metallic layer 106 can itself be a layered laminate and containsa sealant layer 108 on what will be the inside, or product side, of thepackage. This sealant layer 108 is typically formed of a ter-polymer,composed of ethylene, propylene, and butylenes. Printing for the packageis done on the inside of the outer layer and becomes sandwiched betweenthe middle layer 104 and outer layer 102.

Although FIG. 1 depicts the inner layer 102 and outer layer 106 as onlytwo layers, these layers 102, 106 can each include one or more layers. Ametallic layer, such as aluminum, between the OPP layer 106 and theadhesive or polyethylene layer 104 can provide a barrier to retain tasteand freshness of the product contained therein. Other materials used inthese layers are polyester, paper, polyolefin extrusions, adhesivelaminates, polyethylene and other such materials, or a layeredcombination of the above. The package seen in FIG. 1 is referred to inthe art as a “flexible bag” or “pillow pouch,” and is commonly used forpackaging snack foods such as potato chips, tortilla chips, and othervarious sheeted and extruded products.

Vertical form, fill, and seal packaging machines are commonly used inthe snack food industry for forming, filling, and sealing bags of chipsand other like products. FIG. 2 shows an exemplary vertical form, fill,and seal machine that can be used to package snack foods, such as chips.This drawing is simplified, and does not show the cabinet and supportstructures that typically surround such a machine, but it depicts theworkings of the machine well. A continuous web of film 210 ispre-printed with desired graphics such as the product label andnutritional information and includes reference marks known as eye marks.The eye marks are generally a plurality of rectangular ink spots ormarks spaced apart and formed along the edge of the film web. Thepre-printed packaging film 210 is taken from a roll of film web on thesupply spool (also known as the unwind) 212 and passed throughtensioners 214 that keep it taut. The film then passes over a former216, which directs the film as it forms a vertical tube around a productdelivery cylinder 218. This product delivery cylinder 218 normally haseither a round or a somewhat oval cross-section. A registration marksensor is used to detect the eye marks and generate a signal, whichtriggers the cutting process. In other words, the sensor detects themarks and notifies the bag cutting and sealing machine where to cut andseal the bag so the print is aligned properly on the bag. As the tube ofpackaging material is pulled downward by drive belts 220, the edges ofthe film are sealed along its length by a vertical sealer 222, forming aback seal 224. The machine then applies a pair of heat-sealing jaws 226against the tube to form a transverse seal 228. This transverse seal 228acts as the top seal on the bag 230 below the sealing jaws 226 and thebottom seal on the bag 232 being filled and formed above the jaws 226.After the transverse seal 228 has been formed, a cut is made across thesealed area to separate the finished bag 230 below the seal 228 from thepartially completed bag 232 above the seal. The film tube is then pusheddownward to draw out another package length. Before the sealing jawsform each transverse seal, the product to be packaged is dropped throughthe product delivery cylinder 218 and is held within the tube above thetransverse seal 228.

There are a number of desirable features that manufacturers have longstrived to include in packages made on a vertical form, fill, and sealmachine. One exemplary feature is the ability to re-close a package of asnack food that is only partially eaten, so that the flavor and textureof the product are preserved as long as possible. Ordinarily, not all ofa package of snack foods is consumed at one time and thus there is adesire to reseal the package and prevent moisture from causing prematurestaling and spoilage of the contents. Many of the reclosable packagesdisclosed in the prior art utilize a mechanical reclosure means such asinterlocking mechanical profiles or an adhesive reclosure means wherebyat least a portion of the adhesive is adhered to the outside of thepackage to close the package mouth. Use of interlocking strips, however,such as zippers or sliders is costly, and complicates the manufacture ofpackaging. It would be desirable to have a low-cost alternative.

Referring to FIGS. 3 a and 3 b, therein is depicted a prior artpackaging product having a recloseable seal feature, wherein the filmcomprises score lines 30, which pass through all the layers of the film.An upper peelable seal 32 comprising an adhesive layer is then affixedover the scored section of the film. As seen in FIG. 3 a, the upperpeelable seal 32 has an area larger than that of the scored section andcomprises a tear tab 34, which is free from adhesive so that a consumercan grip the tear tab 34 with ease. Thus, as the consumer grips the teartab 34 and pulls it back in the direction of the scored section, thefilm tears along the path of least resistance in the direction providedby the perforated lines 30, creating a large flap on the top side of thepackage. An opening 38 is created in the bag and the adhesive layer 36is exposed as depicted in FIG. 3 b. A consumer can then consume aportion of the contents within the bag through the opening 38 and resealthe opening by sticking the adhesive layer 36 back onto the outer filmlayer of the package.

U.S. Patent Application 2005/0276525 to Hebert et al. discloses arecloseable package that is depicted in FIGS. 4 a and 4 b. However,rather than scoring once through the entire film, Hebert et al. performstwo scoring operations: 1) through an inner portion of the film withscore lines 40 and 2) through an outer portion of the film with scorelines 42. This pressure scoring is possible using laser or mechanicalscoring or cutting. Laser scoring is a process that utilizes a laserbeam to provide a focused spot of energy, which is able to removematerial to a specified depth. The technology is well suited tofabricating high accuracy parts at high speeds, especially flexiblepackaging products. As seen in FIG. 4 a, the outer perforation line 42surrounds the inner perforation line 40. When a consumer grabs the teartab 44, he can peel back the outer (ie, top) portion of the film awayfrom the inner portion, exposing the adhesive layer 46 found between thetwo layers and separating the outer portion from the inner portion ofthe film. Products from within the bag are then fully exposed and canthen be consumed from the opening 48. When the consumer is ready tostore any remaining products within the bag, he can reseal the packageby pressing down around the top side of the package to reduce productexposure to the surrounding environment.

The prior art described above form packages with relatively largeopenings, allowing a consumer to readily consume food products fromwithin the package with relative ease. In fact, the consumer need notgrip the package with both hands to successfully retrieve the productwithin the bag. However, the prior art top flaps, such as those depictedin FIGS. 3 and 4, have a number of significant drawbacks. For example,the flap is scored along a substantial portion of the top side of thebag to form a U-shape, exposing a significant amount of the foodproducts within the bag to its surroundings and making the products moresusceptible to damaging conditions. Further, when attempting to resealthe packages, a consumer must push down along all three edges of theadhesive to adequately seal the bag. This places pressure on asignificant portion of the products behind the seal of the bag. Placingpressure along the bag could cause the consumer to crush the contentsremaining in the bag when it is resealed, resulting in a large amount ofunwanted broken pieces or crumbs. In addition, frequent opening of thepackage causes frequent exposure of the adhesive to the products behindthe top seal. Over time, this exposure causes the items such as unwantedcrumbs to stick to the adhesive, diminishing its adhesive properties andrendering the seal inoperable. Finally, the horizontal packaging, whileeasy to pull open by means of the top flap, is made on a horizontalform, fill and seal machine, which are not typically use for loose fillproducts such as potato chips.

Consequently, because of the speed and productivity achieved on avertical form, fill, and seal machine, a need exists for a flexible bagwith a recloseable seal created using such technology and a single sheetof packaging film. Further, a need exists for a low cost reseal thatoffers minimum surface area from which products are exposed to itssurroundings and allows a consumer to reseal packages without the needto score an entire side of a resulting package and without causing lossof seal adhesion. Finally, a need exists for a resealable package moreakin to the high quality zipper seals often desired without the fear ofdamaging the products behind the seal and without the high costsassociated with zipper seals.

SUMMARY OF THE INVENTION

The proposed invention involves producing a vertical flexible bagconstructed of a single sheet of multi-layered material using a verticalform, fill, and seal machine and having a reclose seal along the top.The flexible bag formed on such a machine comprises an outer film layer,an inner film layer, and an adhesive between the outer and inner filmlayer. In a preferred embodiment, the outer film layer is scored at aposition parallel to and less than two inches from the bottom of the topseal of the bag and to the adhesive middle layer, forming a firsthorizontal score line. More preferably, the first horizontal score lineis less than or equal to approximately 1 inch from the bottom of the topseal, and most preferably equal to approximately 0.25 inches. The innerfilm layer is scored at a position below and parallel to the firsthorizontal line to the adhesive middle layer, forming a secondhorizontal score line that is below the first horizontal line. In oneembodiment, the second horizontal score line is positioned fromapproximately 0.5 to one inch below the first horizontal score line. Thearea between the first and-second horizontal score lines define a singlestraight resealable opening. In an alternate embodiment, only onehorizontal line is scored deep enough to entirely perforate through allthe layers of the film. An upper adhesive seal comprising two differentbond strengths is then placed over the horizontal score line, coveringat least a half inch around the horizontal score line in all directions.Optionally, both embodiments comprise a tamper evident tab that lacksadhesive such that a consumer can pull on the tab to open the package.

The resulting flexible package may be opened, a part of the contentsremoved and the package closed (ie, resealed) to prevent prematuredeterioration of the quality of the contents because of exposure tomoisture in the air. The reseal also prevents damage to the contentswithin the bag because of any pressure necessarily applied whenattempting to reseal the bag. The bag formed as a consequence is asubstantial improvement over prior art resealable bags.

The above as well as additional features and advantages of the presentinvention will become apparent in the following written detaileddescription.

BRIEF DESCRIPTION OF THE DRAWINGS

The novel features believed characteristic of the invention are setforth in the appended claims. The invention itself, however, as well asa preferred mode of use, further objectives and advantages thereof, willbe best understood by reference to the following detailed description ofillustrative embodiments when read in conjunction with the accompanyingdrawings, wherein:

FIG. 1 depicts a cross-section of a typical packaging film known in theprior art.

FIG. 2 depicts a vertical form, fill, and seal machine that is known inthe prior art.

FIG. 3 a depicts a prior art package incorporating a resealable label.

FIG. 3 b depicts the prior art package seen in FIG. 3 a after it hasbeen opened by a consumer.

FIG. 4 a depicts a perspective view of another prior art packageincorporating a resealable feature.

FIG. 4 b depicts a perspective view of the prior art package of FIG. 4 aafter it has been opened by a consumer.

FIG. 5 a depicts a perspective view of one embodiment of-a flexible,resealable package of the instant invention.

FIG. 5 b depicts the embodiment of FIG. 5 a after a consumer has peeledopen the resealable opening.

FIG. 6 a depicts a perspective view of a second embodiment of aflexible, resealable package of the instant invention.

FIG. 6 b depicts the embodiment of FIG. 6 a after a consumer has openedthe flexible, resealable package of the present invention.

Where used in the various figures of the drawing, the same numeralsdesignate the same or similar parts. All figures are drawn for ease ofexplanation of the basic teachings of the present invention only; theextensions of the figures with respect to number, position,relationship, and dimensions of the parts to form the preferredembodiment will be explained or will be within the skill of the artafter the following teachings of the present invention have been readand understood. Further, the exact dimensions and dimensionalproportions- to conform to specific force, weight, strength, and similarrequirements will likewise be within the skill of the art after thefollowing teachings of the present invention have been read andunderstood.

DETAILED DESCRIPTION

FIGS. 5 and 6 depict two embodiments of the package of the presentinvention, which may be closed after being opened (ie, resealed) topreserve moisture sensitive food products, including but not limited tosnack chips. The packages are made using a vertical form, fill, and sealmachine and a flexible packaging film having at least three layers. In apreferred embodiment, an adhesive layer is pattern applied in betweenouter and inner film layers, preferably a pressure sensitive adhesive isplaced in between an outer and inner score line and forms a bond inbetween the outer and inner film layers when pressure is applied acrossthe top portion of the resulting package. As described above, and asseen in FIG. 2, in a vertical form, fill, and seal machine, a length ofplastic film is formed into a vertical tube around a product deliverycylinder. The vertical tube is vertically sealed along its length toform a back seal and is transversely sealed to form top and bottom sealsdelineating individual packages, which are then cut from the verticaltube.

As used herein, the term “score lines” encompasses lines, notches orincisions that have been cut into the material or a portion of thematerial, perforating the film to enable it to be separated easily fromadjoining portions of the adjacent material or sections. As used herein,“reclose strip” is synonymous with reseal. Applicants use the terms“peelable” and “releasable” interchangeably to refer to the side of theadhesive comprising a lower bond strength as compared to its opposingside. This provides for release of the peelable side of the adhesivefrom a first adjacent surface of a layer, while allowing for a morepermanent bonding to a second adjacent surface of another layer when thelayers surrounding either side of the adhesive are pulled apart by aconsumer.

FIGS. 5 a and 5 b depict a perspective view of a first embodiment of theflexible, resealable package of the instant invention. As seen in FIG. 5a, the flexible film of the package has been scored along a horizontalline 50. The flexible film is cut all the way through the film (ie,perforated through each of its layers) at line 50 substantially parallelto the top seal 52 of the package. Preferably, the score line 50 shouldbe as close as possible to the bottom of the top seal, as illustrated inFIG. 5 a by the distance X. In one embodiment, the score line 50 is lessthan about 2 inches from the bottom of the top seal and more preferablyabout one inch from the bottom of the top seal. The score line 50 can beperformed by any means known-in the art including without limitation diecutting or laser scoring. The ends of the score line 50 contain a slightdeviation or curve from the line 50, in either an up or down direction,to provide for a tear stop for decreased propagation, which prevents thepackage from tearing beyond- the length of the score line 50 and fromforming inconsistent tear lines beyond the scope of the score line 50.

Affixed over the score line 50 is a strip or label 54, which is centeredover the score line 50 to cover a length of about half an inch in eachdirection surrounding the score line 50. The label 54, contains apattern-applied adhesive with at least two different bond strengths. Onits inner side facing the outer side of the film of the bag and belowthe score line 50 (referred to as the lower portion), the affixed label54 comprises an adhesive with a bond strength higher than that of theportion above the score line 50 (referred to as the upper portion),causing the lower portion to remain affixed to the outer film layerbelow the score line 50 when the label is pulled outward from the bag bya consumer. The upper portion of the affixed label 54 contains apressure-sensitive adhesive 56 with a lower bond strength (typicallyfrom about 20 to 1,600 grams per inch width) than the adhesive of thelower portion of the label 54 (typically from about 100 to 4,000 gramsper inch width, depending on the strength of the upper portion).Consequently, the upper portion of the label 54 comprises a peelableinner side that releases from the film of the package while the lowerportion remains more permanently bonded to the film, forcing the film totear along the scored line 50 when the label 54 is pulled away-from thefilm by a consumer.

After the film is scored and the label 54 affixed, the film is then runthrough a vertical form, fill and seal machine, as previously discussedin relation to FIG. 2, to form the bag seen in FIGS. 5 a and 5 b. Thegraphics on the packaging film can-be oriented in either the directionof film travel or perpendicular to the direction of the film travel.FIG. 5 b demonstrates the bag after it has been opened by a consumer. Asseen in FIG. 5 b, the opening 58 of the resulting flexible bag exposesthe pressure-sensitive adhesive 56 to the inner side of the bag. Theadhesive will then be able to reseal with the portion of the packageabove the score line 50 when pressure is placed along the seal by aconsumer.

FIGS. 6 a and 6 b depict a second and preferred embodiment of thepresent invention, wherein offsetting cuts are made on the inside andoutside layers (ie, sides) of the flexible film. As used herein,“offset” is used to mean non-overlapping such that the cuts made on thetwo sides of the flexible film form parallel score lines, but do notoverlap or meet and do not completely perforate or cut the packagecompletely through each layer along parallel planes of the film layers.By creating offsetting cuts on the two sides of the flexible film layer,two lines of weakness are formed which define a straight opening in thefront side of the bag, as depicted in FIG. 6 b, when the front and backsides are grabbed by the index finger and thumb and pulled away from oneanother. Thus, the film layers will comprise offsetting cuts at specificsides of the film and define a straight releasable opening along oneside of the bag.

As described above in relation to FIG. 1, the film created for packagingproducts typically comprises an outer film layer 102 and an inner filmlayer 106 (which can each include one or more layers of materials) aswell as a layer 104 sandwiched in between, which is comprised of eitheran adhesive or polyethylene. Consequently, as used herein, the terms“outer film layer” and “inner film layer” are meant to include one ormore layers of materials on opposite sides of a film. In one embodiment,the sandwiched layer 104 can comprise both an adhesive layer and apolyethylene, which will make the bag stiffer, thicker, and morepuncture resistant.

FIG. 6 a demonstrates the second and preferred embodiment of the packagein its sealed condition. A plurality of lines have been scored throughthe outer film layer of the flexible film package to the adhesive layeralong a score line 60 in a line substantially parallel to, and at adistance X from, the bottom of the top seal 70 and perpendicular to theside edges of the web. The scoring forms an outer score line 60 throughthe outer film layer 102, which as described above can comprise one ormore layers of materials. As depicted in FIG. 6 a, the optional tear tabforms a curve or semicircle towards the top seal in the center of thescore line 60. The tear tab does not comprise any adhesive in betweenthe outer and inner sides of the film in order to provide a consumerwith easy grip and access to opening the package. The cut is made by anymeans known in the art including without limitation laser or mechanicalcutting. Preferably, the outer score line 60 is no more than two inchesfrom the bottom of-the top seal 70. Thus, the distance X, as seen inFIGS. 6 a and 6 b, should be less than two inches, more preferably lessthan or equal to about one inch and most preferably equal to about 0.25inches. A plurality of lines is also scored through the innermost layer106 to the adhesive layer, forming a second and parallel score line 62on the inner (opposite) film layer. The score line 62 is a distance Ybelow the score line 60, where Y ranges from about 0.5 to 1 inch (notincluding the optional tab in its center). The scoring of the secondparallel score line 62 can be performed simultaneously or separatelyfrom the scoring of the first horizontal line. Together with score line60, score line 62 defines a resealable opening. Further, one skilled inthe art, armed with this disclosure, will recognize that the score lines60, 62 can be placed on the packaging film either during or after filmformation before it is rolled into the supply spool 212. In oneembodiment, the outer and inner score lines both comprise a tear stop ateach of its ends for decreased propagation.

Adhesive layers of different bond strengths are applied throughout thefilm layers of the bag and in between the outer layer and the innerlayer of the film web during film formation. In one embodiment, theadhesive layer comprises at least two different bond strengths. Apressure sensitive adhesive 66 is pattern applied in between the outerscore line 60 and the inner score line 62, defined as Y in FIG. 6 a,within the film that makes up the front side of the bag. This pressuresensitive adhesive 66 comprises a peelable side, which has a lower bondstrength than that of the adhesive layer applied throughout the rest ofthe film in between the outer and inner layers. In other words, the bondstrength of at least one side of the pressure sensitive adhesive appliedin between the first horizontal (outer) score line 60 and the secondhorizontal (inner) score line 62 is less than that of any adhesivebetween the outer and inner layers throughout the film of the flexiblebag. This allows for one side of the adhesive to be releasable from afirst adjacent side in between the inner layer and outer layer of thebag. Generally, the bond strength of a releasing pressure-sensitiveadhesive is between about 25 to about 1,600 grams per inch width, whilethe bond strength of the opposing side of the adhesive ranges frombetween about 100 to 4,000 grams per inch width or higher, so long asthe latter bond strength is higher than that of the former to create amore permanent bond which has a more aggressive adhesive. Thus, a firstside of the adhesive is peelable from to a first adjacent surface, whilethe second side of the adhesive is more strongly adhesive to a secondadjacent surface. Any adhesive in between the outer and inner layersthroughout the rest of the package away from the outer and inner scorelines will also comprise a higher bond strength than the peelable side.In one embodiment, the peelable side of the pressure-sensitive adhesive66 has a bond strength ranging from approximately 25 to 1,600 grams perinch width and is adjacent to an inner film layer, while the oppositeside has a stronger adhesive bond strength ranging from 100 to 4,000grams per inch width and is adjacent to an outer film layer, such thatupon separation by a consumer, the peelable adhesive will release fromthe inner film layer. In another embodiment, the peelablc adhesive has abond strength ranging from approximately 200-800 grams per inch width,while the opposite (more permanently-bonded) side has a bond strengthranging from approximately 800-4000 grams per inch width. Thus, astraight resealable opening 64, seen in FIG. 6 b, is formed at the topof the bag between the first outer score line and second inner scoreline when the front and back sides of the bag are pulled apart orseparated by a consumer. The pattern applied pressure-sensitive adhesive66 remains bonded to the surface with which it more permanently bondedand is exposed on the inner side of the outer film layer. The adhesive66 can then engage the exposed area 68 of the inner layer to form thereseal under pressure imposed by a user such as pressing along section Yon the outside of the bag towards the exposed area 68. Alternatively,one skilled in the art, armed with this disclosure, will also recognizethat the bond strength of the pattern-applied adhesive can also beadjusted such that the adhesive 66 remains on the exposed area 68. Thus,the adhesive layer 66 within the front side of the package wallreleasably adheres the inner and outer layers of the film back togetheronce separated by a consumer.

To form the package shown in FIGS. 6 a and 6 b, after formation andscoring of the film, it is then placed on the supply spool 212 of avertical form, fill and seal machine, as discussed in relation to FIG. 2in the prior art. As discussed previously, a registration mark sensorwill detect the eye marks pre-printed on the scored film to align thefilm properly such that the reseal is at the top of the bag and ensurethat the package is sealed and cut at the proper locations. The verticalform and fill machine thus operates as previously described in the priorart, with the vertical seal along its length to form a back seal and atransverse seal along its bottom to form a bottom seal. Product is thenintroduced through the forming tube 218 into the sealed tube ofpackaging film, and the upper transverse seal being formed within 2inches of the reseal, thereby forming a top seal 70 and completing thepackage. As used herein the top and bottom seals are used to encompassseals made between two adjacent film layers by applying heat and/orpressure (ie, between sealing jaws) for a given dwell time.

As shown in FIG. 6 a, the flexible package formed comprises a width Wand a length L. A plurality of score lines formed along the outer filmportion 102 and the plurality of score lines formed along inner filmportion 106 define an opening 64 having a length L₁. The length L₁ isapproximately 83% to 99% of the width W of the bag, and more preferably,about 91% to about 98% of the width W of the bag. In other words, theratio of the length of the opening L₁ to the width W ranges fromapproximately 9:10 to approximately 49:50. In another embodiment, thelength L₁ of the opening ranges from approximately 25% to approximately68% versus the length L of the bag, resulting in a ratio for the openingto length.of.the bag ranging from between approximately 1:4 toapproximately 34:50.

After opening, the packages of the two embodiments described above canthen be reclosed by applying pressure across the top of the package. Thepackage can then be re-opened and re-closed as desired by the consumer.Referring to FIGS. 5 a, 5 b, 6 a and 6 b, while the reseal 50, 60 isfunctional anyplace on the package, it is desirable that the strip beapplied on the upper half of the resulting package and as close aspossible to the bottom of the top seal, preferably less than 2 inchesfrom the bottom of the top seal 52, 70 of the resulting package. Placingthe reseal 50, 60 on the lower half of the bag could cause the user tocrush the contents remaining in the bag when it is resealed.

The present invention offers an economic method of producing anincorporated reseal function without modification of the vertical form,fill and seal machines used to continuously and effectively producesnack food packages. The invention is further an improvement overmethods for including reseal functions on snack food packages. While theinvention has been particularly shown and described with reference to apreferred embodiment, it will be understood by those skilled in the artthat various changes in form and detail may be made therein withoutdeparting from the spirit and scope of the invention.

1. A flexible bag formed on a vertical form, fill and seal machinehaving a top seal, said bag containing a product and further comprising:an outer film layer; an inner film layer; an adhesive layer between saidouter film layer and said inner film layer; a first horizontal scoreline through said outer film layer to the adhesive layer, wherein saidfirst horizontal score line is parallel to and less than two inches fromthe bottom of said top seal; a second horizontal score line through saidinner film layer to said 10 adhesive layer, wherein said secondhorizontal score line is below and parallel to said first horizontalscore line; and wherein the first and said second score lines define aresealable opening on said bag.
 2. The flexible package of claim 1wherein said first horizontal score line comprises a tear tab.
 3. Theflexible package of claim 1 wherein said adhesive layer comprises apeelable side.
 4. The flexible package of claim 1 wherein said first andsecond horizontal score lines each comprise a tear stop on both ends. 5.The flexible package of claim 1 wherein the length of said resealableopening is approximately 91% to 98% of the width of said bag.
 6. Theflexible package of claim 1 wherein the length of said resealableopening is approximately 25% to 68% of the length of said bag.
 7. Amethod for making a flexible reclosable package on a vertical form,fill, and seal machine, wherein the reclosable package is comprised of aflexible packaging film of a continuous web having at an outer filmlayer, an inner film layer, and an adhesive layer applied in betweensaid outer and inner film layers, said method comprising the steps of:a) scoring a plurality of lines through the outer film layer of saidcontinuous web, wherein said lines are perpendicular to the side edgesof the web, thereby forming an outer score line; b) scoring a pluralityof lines through the inner layer within 0.5 to 1 inch from and parallelto the plurality of outer layer score lines, thereby forming a an innerscore line; c) feeding the web into said vertical form, fill and sealmachine; and d) forming said flexible reclosable package wherein saidouter score line is less than two inches from a top seal of said formedpackage.
 8. The method of claim 7, wherein step a) further comprises thestep of scoring a tear tab into the center of the outer score line. 9.The method of claim 7, wherein steps a) and b) further comprise the stepof forming tear stops at the ends of the outer and inner layer scorelines.
 10. The method of claim 7, further comprising the step ofapplying a pressure sensitive adhesive in between the outer score lineand the inner score line, said adhesive having at peelable side.
 11. Themethod of claim 7, wherein steps a) and b) define an opening formed inbetween said outer score line and said inner score line, said openinghaving a length that is 91%-98% of the wvidth of said flexiblerecloseable package.
 12. A vertical flexible reclosable package formedby the method of claim 7.